Production Process and Technical Specifications for Plastic Tableware Made from Sugarcane Bagasse
Complete Manufacturing Process from Raw Material to Finished Product with Quality Control Standards
Sugarcane bagasse is a fibrous by-product generated during the sugar production process of sugarcane. According to data from the China Sugar Industry Association in 2023, China produces approximately 8 million tons of sugarcane bagasse annually. Utilizing sugarcane bagasse to produce tableware can achieve the resource utilization of agricultural waste. For every 10,000 tons of sugarcane bagasse utilized, approximately 12,000 tons of CO₂ emissions can be reduced (data source: calculation by the Ministry of Ecology and Environment in 2024).
Environmental Value and Industrial Background
The production of sugarcane bagasse tableware represents a significant advancement in sustainable manufacturing, transforming agricultural waste into valuable eco-friendly products while reducing environmental impact and creating economic opportunities in rural communities.
Raw Material Procurement and Preprocessing Specifications
Stringent quality standards ensure the consistency and safety of raw materials throughout the production process.
Raw Material Quality Standards
According to the GB/T 36787-2018 standard for "Paper Moulded Tableware": Fiber length: 1.5 - 2.5mm, Impurity content: ≤ 0.5%, Moisture content: ≤ 12%, Storage conditions: Temperature ≤ 30℃, Relative humidity ≤ 60%.
Raw Material Pre-treatment Process
Cleaning and Decontamination: Utilize a three-stage counter-flow cleaning system, Water quality requirements: Comply with the GB 5749 standard for drinking water, Water consumption: Per ton of product, water consumption ≤ 8 tons.
Whitening Treatment (Optional): Bleaching agent: Hydrogen peroxide, dosage 0.5 - 1.5%, Temperature: 70 - 80℃, Time: 60 - 90 minutes, Whitening range: 75 - 85% (ISO standard).
Pulping Process Technical Parameters
The pulping process transforms raw sugarcane bagasse into a workable material suitable for tableware production.
Fiber Separation
Equipment: Hydraulic Pulverizer, Concentration: 3-5%, Time: 20-30 minutes, Energy Consumption: Electricity consumption per ton of pulp ≤ 80 kWh.
Blending System
Basic Formula (Standard of the China Food Packaging Industry Association, 2024): Sugarcane Juice: 60-80%, Bamboo Juice: 15-25%, Reinforcing Fibers: 5-15%.
Additives Addition: Waterproofing Agent: 1.0 - 2.0% (in accordance with GB 9685 standard), Reinforcing Agent: 0.5 - 1.0%, Wet Strength Agent: 0.3 - 0.8%.
| Process Parameter | Specification | Standard |
|---|---|---|
| Fiber Length | 1.5-2.5mm | GB/T 36787-2018 |
| Pulping Concentration | 3-5% | Industry Standard |
| Energy Consumption | ≤80 kWh/ton | Energy Efficiency |
| Water Consumption | ≤8 tons/ton product | Environmental Standard |
Forming and Hot Pressing Process
The forming and hot pressing stages are critical for achieving the desired product shape, strength, and durability.
Vacuum Forming
Vacuum Degree: -0.08 to -0.1 MPa, Forming Time: 15 - 25 seconds, Fiber Retention Rate: ≥ 85%.
Hot Pressing and Shaping Process
Process Parameters: Temperature: 180 - 220℃, Pressure: 2 - 5 MPa, Time: Adjusted according to product thickness (45 seconds for a 1.5mm thickness), Energy Consumption: ≤ 120 kWh per ton of product.
Quality Indicators: Thickness Tolerance: ±0.2mm, Density: 0.6 - 0.8g/cm³, Moisture Content: ≤10%.
Post-processing Procedures
Post-processing ensures the final product meets aesthetic and functional requirements while maintaining quality standards.
Edge Trimming Process
Equipment: CNC Edge Trimming Machine, Precision: ±0.3mm, Waste Recovery Rate: ≥95%.
Surface Treatment
Coating Process: PLA Coating: Thickness 10-15 μm, Natural Wax Coating: Thickness 5-8 μm, Waterproof Grade: IPX3, Oil Resistance Time: ≥ 4 hours (120℃).
Quality Inspection System
Comprehensive quality control measures ensure product safety, durability, and compliance with industry standards.
Physical Performance Testing
According to the GB/T 27589-2011 standard:
Load Testing: Plates: ≥ 3.0 kg, Bowls: ≥ 2.5 kg, Drop Test: No damage at a height of 0.8 meters.
Sealing Test: Water Temperature: 100℃, Duration: 30 minutes, Result: No leakage.
Safety Performance Testing
Heavy Metal Migration: Lead: ≤ 0.01mg/dm², Cadmium: ≤ 0.002mg/dm², Mercury: Not detected (Compliant with GB 31604.1-2015 standards).
Microbial Indicators: Total Colony Count: ≤ 100 CFU/g, Coliform Bacteria: Not Detected, Mold: ≤ 50 CFU/g.
Metal Detection and Quality Control
Advanced detection systems ensure product safety and quality consistency throughout the production process.
Online Inspection System
Detection Sensitivity: Fe ≥ 1.5mm, SUS ≥ 2.0mm, Inspection Speed: ≥ 120 pieces per minute, Automatic Elimination Rate: 100%.
Verification of Water and Oil Resistance Properties
Rigorous testing ensures products meet performance requirements for various food service applications.
Test Standards
According to GB/T 22805-2008:
Waterproof Test: Conditions: 100℃ water, 30 minutes, Requirements: No leakage, no deformation.
Oil Resistance Test: Conditions: 120℃ cooking oil, 30 minutes, Requirements: No penetration, no softening.
Packaging and Warehousing Management
Environmentally responsible packaging and proper storage conditions maintain product quality and support sustainability goals.
Environmental Packaging
Materials: Biodegradable film, Printing: Water-based ink, Recycling logo: Clearly marked.
Storage Conditions
Temperature: 15 - 30℃, Humidity: 40 - 60%, Stack height: ≤ 5 layers, Shelf life: 24 months.
Environment and Social Responsibility
The production of sugarcane bagasse tableware contributes to environmental protection and social development through sustainable practices.
Environmental Impact Assessment
Carbon Emissions: Carbon emissions per ton of product: 0.9 tons of CO₂ equivalent, Reduced compared to traditional plastics: 72%.
Resource Consumption: Water cycle utilization rate: ≥ 95%, Raw material utilization rate: ≥ 92%.
Social Responsibility
Job Creation: Direct employment: 50 people per ton of production capacity, Indirect employment: 200 people per ton of production capacity.
Increased Income for Farmers: Income increase per ton of sugarcane residue: 150 - 200 yuan, Beneficiary farmers: 5,000 households per year.
Technological Innovation and Development Trends
Continuous innovation drives improvements in efficiency, quality, and environmental performance.
Process Optimization Directions
Energy-saving Technologies: Waste Heat Recovery System, Intelligent Energy Consumption Management, Application of Clean Energy.
Quality Enhancement: Nanocellulose reinforcement, Intelligent detection system, Digital quality management.
Market Prospects
According to the forecast by the National Development and Reform Commission: Market size in 2025: 8 billion yuan, Annual growth rate: 25%, Export proportion: 35%.
Conclusion
The production process of sugarcane residue molded tableware is achieved through scientific proportioning, precise control and strict testing, ensuring that the products maintain environmental protection features while having excellent performance. This process not only realizes the high-value utilization of agricultural waste but also provides a feasible solution for plastic pollution control. With the advancement of technology and the growth of market demand, sugarcane residue tableware will play an increasingly important role in the field of environmental packaging, contributing to sustainable development and circular economy goals.